Building blocks with integrated assembling design

ABSTRACT

A new building material made of chopped straw, cement, mortar cement or lime combined together with a bonding agent is pressed into building blocks of different sizes and shapes. The blocks come in different sizes and shapes to serve different building needs and/or to fit an integrated assembly system. The blocks are interlocked or fitted to correspond to specific requirements. Depending on the proportions of the elements and the pressure exercised to make the blocks, the density can be controlled to increase either the insulation value or the structural value. The grooves, which are part of the interlocking system, can also be filled with concrete either vertically or horizontally or both to create a stronger structure calibrated according to additional structural needs. The resulting concrete structure can also be reinforced with steel rod to further increase its strength. This building material is highly adaptable and environmentally friendly.

TECHNICAL FIELD

This invention is related to the field of building construction and morespecifically to a new building material and building blocks.

BACKGROUND OF THE INVENTION

In 1981, Louis Gagné built his first straw bales and mortar house. Theobjective was an affordable house which was well insulated, structurallysound, simple and easy to build. Louis Gagné received a CMHC grant totest this wall system, and published the results in the followingreport: GAGÉ, Louis, A Straw Bales And Mortar House DemonstrationProject, CMHC, Ottawa, Canada, 1986. This report reveals the exceptionalfire resistance, the structural soundness and the insulation value ofthis straw bales and mortar building method. It is generally known thatstraw is a hollow stem derived from agriculturally produced cereals,which is traditionally used for bedding in stables, thatching, stuffing,insulating, etc. Furthermore, straw is commonly available in the form ofbales. In the following years, Louis Gagné went on building with strawbales, using concrete for the structure instead of mortar, perfectingthe techniques used to erect the walls, refining the process and theresults. In spite of these improvements, building with straw bales andconcrete remains a method with limited commercial value, because it is alabour intensive process where individuals build singles houses, andwhere standards are hard to define since the bales from the field escapecontrol as to size and density.

In the last few years, Louis Gagné stopped building with straw bales andconcrete because the development of this building approach seems to havereached its full potential.

Accordingly, an improved building material and building method is highlydesirable.

SUMMARY OF THE INVENTION

One aspect of the present invention provides a building material made ofchopped straw mixed with Portland cement, mortar cement or lime and apolymer emulsion diluted in water which acts as the bonding agent.

In another aspect of the present invention, the resulting material iscompressed into blocks of different sizes and shapes.

In another aspect of the present invention, the proportion and thecombination of the elements (chopped straw, Portland cement, mortarcement or lime and polymer emulsion diluted in water) as well as thepressure exerted to make the blocks, can be modified to increase ordecrease the density of the blocks.

In still another aspect of the present invention, the chopped straw(mainly cereal straw such as wheat, rye, barley, oats and rice whereavailable) of ideal lengths comprise between 5 cm and 10 cmsubstantially (the straw lengths can be shorter or longer) is the fillerelement and represents the bulk of the block's volume. The cementsurrounding each piece of straw gives it rigidity and strength. Thegluing factor and the adherence of the cement to the pieces of straw isprovided by a polymer emulsion diluted and water.

In yet another aspect of the present invention, this solution can bealso mixed with mortar cement or lime or both in order to provide abetter adherence of the cement to the pieces of straw.

In still another aspect of the present invention, while straw constitutethe bulk of the volume of the building material, the proportion ofstraw, Portland cement, mortar cement or lime and the polymer emulsiondiluted in water is one of the factors which determine the density ofthe blocks. Therefore, if the amount of cement is augmented in the mix,the density of the block will increase, and hence its structural valuewill also be increased. If the mix is made to be lighter by increasingthe proportion of straw and using less cement, the blocks will have lessstructural value but a higher insulating value.

In another aspect of the present invention, the density of the blockswill vary with the compression force used to make the blocks. Increasingthe pressure to form a block will increase its density and itsstructural value. Diminishing the pressure to form a block will reduceits structural value while increasing its insulating factor.

In another aspect of the present invention, the sizes of the blocks canbe changed to suit different building needs. If the width of the blockis increased, the structural value and the insulating factor areincreased, and a larger volume of concrete could also be poured toincrease the structural strength of the wall. If the length and theheight of the block is increased it will take less time and fewer blocksto build a wall.

In another aspect of the present invention, the shapes of the blocks aredesigned to fit together as a four interlocking blocks system, in whicha first block is shaped with a horizontal groove on top, a flat bottom,a vertical groove on one side and a vertical tongue on the oppositeside; a second block shaped with an horizontal groove on top, a flatbottom and a vertical groove on each side; a third block shaped with anhorizontal groove on top, an horizontal tongue on the bottom, a verticalgroove on one side and a vertical tongue on the opposite side; and afourth block shaped with an horizontal groove on top, an horizontaltongue on the bottom and a vertical groove on each side are used eitherto build a wall directly by interlocking the blocks together or to builda wall with a concrete structure by setting together the vertical andhorizontal grooves at chosen intervals which can be filled with concretethat can be reinforced or not with steel rods.

In another aspect of the present invention, the surfaces of the wall canbe finished by applying directly coats of mortar, stucco or plaster onthose surfaces depending on the building requirements.

One broad aspect of the present invention provides a building materialfor the construction of building blocks, the building materialcomprising: chopped straw; Portland cement; mortar cement or lime; and abonding agent comprising a polymer emulsion, wherein the straw ischopped in lengths substantially between 50 mm and 100 mm.

In some embodiments, the straw comprises the bulk of the volume of thebuilding material.

In some embodiments, the straw comprises cereal straw.

In some embodiments, the cereal straw is selected from the group ofwheat, rye, barley, oats and rice.

In some embodiments, the bonding agent further comprises at least oneof: mortar cement and lime.

Other embodiments provide a building block formed of the buildingmaterial, the building block having a generally solid rectangularexterior configuration.

In other embodiments the building block comprises a front face; a rearface opposite the front face; a top surface adjacent to the front faceand the rear face, the top surface having a horizontal groovesubstantially parallel to the front face; a bottom surface adjacent tothe front face and the rear face, and opposite the top surface; a firstend face adjacent to: the front face; the rear face; the top surface;and the bottom surface, the first end face having a vertical groovesubstantially parallel to the front face; and a second end face adjacentto: the front face; the rear face; the top surface; and the bottomsurface, the second end facing being opposite the first end face.

In some embodiments, the second end face has a vertical groove,substantially parallel to the front face.

In other embodiments, the second end face has a vertical tongue,substantially parallel to the front face, the vertical tongue configuredto mate with a corresponding vertical groove of an adjacent similarbuilding block.

In some embodiments, the bottom surface is substantially flat.

In other embodiments, the bottom surface has a horizontal tonguesubstantially parallel to the front face, the horizontal tongueconfigured to mate with a corresponding horizontal groove of an adjacentsimilar building block below.

Another embodiment of the present invention provides a building blocksystem comprising a plurality of building blocks, the building blocksselected from one or more of: a first block having a horizontal grooveon a top surface, a flat bottom surface, a first end face having avertical groove and a second end face having a vertical groove; a secondblock having a horizontal groove on a top surface, a flat bottomsurface, a first end face having a vertical groove and a second end facehaving a vertical tongue; a third block having a horizontal groove on atop surface, a horizontal tongue on a bottom surface, a first end facehaving a vertical groove and a second end face having a vertical groove;a fourth block having a horizontal groove on a top surface, a horizontaltongue on a bottom surface, a first end face having a vertical grooveand a second end face having a vertical tongue, the system permittingbuilding of a wall by stacking courses of blocks selected from the firstblock, second block, third block and fourth block such that blocks canbe selected to mate vertical tongues with corresponding vertical groovesor to arrange facing vertical grooves of adjacent blocks to allow forfilling the resulting vertical cavity with reinforcing concrete, asrequired.

In some embodiments the blocks can be selected to mate horizontaltongues of blocks in a second course with corresponding horizontalgrooves of blocks in a first course or to allow filling the continuoushorizontal groove formed by the horizontal grooves of adjacent blocks inthe first course with reinforcing concrete, and subsequently stacking asecond course of blocks with flat bottom surfaces, as required.

Yet another embodiment of the invention provides a method ofconstructing a wall of a plurality of courses of building blocks, theblocks selected from a set of blocks wherein: a first block has ahorizontal groove on a top surface, a flat bottom surface, a first endface having a vertical groove and a second end face having a verticalgroove; a second block has a horizontal groove on a top surface, a flatbottom surface, a first end face having a vertical groove and a secondend face having a vertical tongue; a third block has a horizontal grooveon a top surface, a horizontal tongue on a bottom surface, a first endface having a vertical groove and a second end face having a verticalgroove; a fourth block has a horizontal groove on a top surface, ahorizontal tongue on a bottom surface, a first end face having avertical groove and a second end face having a vertical tongue, themethod comprising steps of: laying a first course of blocks having aflat bottom surface, end-to-end such that where a reinforcing column isnot required, adjacent blocks are selected to mate a vertical groove ofone block with a corresponding vertical tongue of an adjacent block; orwhere a reinforcing column is required, adjacent blocks are selected topresent facing vertical grooves to form a vertical cavity between theadjacent blocks; filling any vertical cavities in the first course withreinforcing concrete; where horizontal reinforcement is not required,laying a subsequent course of blocks having horizontal tongues to matewith the horizontal grooves of the preceding course below; or wherehorizontal reinforcement is required, filling the continuous horizontalgroove formed by the horizontal grooves of adjacent blocks of thepreceding course below with reinforcing concrete and laying a subsequentcourse of blocks with flat bottom surfaces, end to end; and filling anyvertical cavities in the subsequent course with reinforcing concrete.

Some embodiments further comprise a step of gluing adjacent blockstogether with a mortar slurry.

Other embodiments further comprise a step of gluing adjacent blockstogether with grout.

In some embodiments the vertical spaces of each course align with thevertical spaces of the preceding course below.

Some embodiments further comprise a step of placing reinforcing rods inreinforcing concrete in the aligned vertical cavities.

Some embodiments further comprising a step of placing reinforcing rodsin the reinforcing concrete in the continuous horizontal groove.

Other embodiments of the present invention further comprise a step ofapplying a finish coat directly to the wall, the finish coat selectedfrom the group of mortar, stucco and plaster.

BRIEF DESCRIPTION OF THE DRAWINGS

Further features and advantages of the present invention will becomeapparent from the following detailed description, taken in combinationwith the appended drawings, in which:

FIG. 1 shows a perspective view of an embodiment of a first block of thepresent invention,

FIG. 2 shows a perspective view of an embodiment of a second block ofthe present invention,

FIG. 3 shows a perspective view of a first and second block interlockedtogether horizontally in accordance with an embodiment of the presentinvention,

FIG. 4 shows a perspective view of an embodiment of a third block of thepresent invention,

FIG. 5 shows a perspective view of an embodiment of a fourth block ofthe present invention,

FIG. 6 shows a perspective view of third and fourth block interlockedtogether horizontally in accordance with an embodiment of the presentinvention,

FIG. 7 shows a perspective view of a fourth block interlocked verticallywith a preceding course of second blocks in accordance with anembodiment of the present invention.

FIG. 8 illustrates a step of method to build a reinforced wall inaccordance with an embodiment of the present invention, wherein a firstcourse of blocks is laid with resulting vertical channels,

FIG. 9 illustrates a step of method to build a reinforced wall inaccordance with an embodiment of the present invention, wherein thevertical channels are filled with concrete,

FIG. 10 illustrates a step of method to build a reinforced wall inaccordance with an embodiment of the present invention, wherein thecontinuous horizontal groove formed by the horizontal grooves ofadjacent blocks in the first course are filled with reinforcingconcrete,

FIG. 11 illustrates a step of method to build a reinforced wall inaccordance with an embodiment of the present invention, wherein a secondcourse of blocks is laid, in alignment with the preceding course ofblocks,

FIG. 12 illustrates a step of method to build a reinforced wall inaccordance with an embodiment of the present invention, wherein anadditional block is laid on the second course,

FIG. 13 illustrates a step of method to build a reinforced wall inaccordance with an embodiment of the present invention, wherein thevertical channels and the continuous horizontal groove of the secondcourse is filled with concrete,

FIG. 14 illustrates a step of method to build a partially reinforcedwall using a combination of blocks in accordance with an embodiment ofthe present invention, wherein a first course of blocks is laid,

FIG. 15 illustrates a step of method to build a partially reinforcedwall using a combination of blocks in accordance with an embodiment ofthe present invention, wherein a vertical channel is filled withconcrete,

FIG. 16 illustrates a step of method to build a partially reinforcedwall using a combination of blocks in accordance with an embodiment ofthe present invention, wherein a second course of blocks is laid,interlocking with the preceding course,

FIG. 17 illustrates a step of method to build a partially reinforcedwall using a combination of blocks in accordance with an embodiment ofthe present invention, wherein an additional block is laid on the secondcourse, defining a vertical space,

FIG. 18 illustrates a step of method to build a partially reinforcedwall using a combination of blocks in accordance with an embodiment ofthe present invention, wherein the vertical channel is filled withconcrete, and

FIG. 19 illustrates a step of method to build a partially reinforcedwall using a combination of blocks in accordance with an embodiment ofthe present invention, wherein the continuous horizontal groove of thesecond course is filled with concrete.

DETAILED DESCRIPTION

The building material is made of straw chopped in lengths of between 5cm and 10 cm substantially (These are ideal lengths but it can beshorter or longer.) mixed with Portland cement, mortar cement or limeand a polymer emulsion diluted in water which acts as a bonding agent.These different ingredients are well mixed together and then pressedinto blocks of different sizes and shapes. The density of the blocksdepends on the proportions by which the different ingredients arecombined together as well as on the pressure exerted to compress theblocks. The density of the blocks also determines the structural valueand the insulation value. Increased density provides more structuralvalue while decreased density provides more insulation value.

The blocks are fabricated in four different shapes that can be used in abuilding system and method to be either stacked and interlocked orassembled to allow for concrete structural reinforcement.

In an embodiment of the present invention, there are four differentshapes of blocks. As shown in FIG. 1, a first block 1 has a horizontalgroove 5 on a top surface, a flat bottom 6 and a vertical groove 7 oneach end face. As shown in FIG. 2 a second block 2 has a horizontalgroove 5 on a top surface, a flat bottom 6, a vertical groove 7 on afirst end face and a vertical tongue 8 on a second end face.

FIG. 3 shows how block 2 and block 1 are interlocked together at 10 withrespective vertical tongue and groove and how the two aligned blocksproduce a continuous horizontal groove 13 on top and a vertical groove 7on each external end face.

FIG. 4 illustrates a third block 3 which has a horizontal groove 5 onthe top surface, a horizontal tongue 11 on the bottom surface and avertical groove 7 on each end face.

FIG. 5 illustrates a fourth block 4 which has a horizontal groove 5 onthe top surface, a horizontal tongue 11 on the bottom surface, avertical groove 7 on a first end face and a vertical tongue 8 on asecond end face.

FIG. 6 shows how block 4 and block 3 are interlocked together at 10 withrespective vertical tongue and groove and how the two aligned blocksproduce a continuous horizontal groove 13 on top, a continuous tongue 14on the bottom and a vertical groove 7 on each external end face.

FIG. 7 shows how block 4 interlocks horizontally at 11 by overlappingthe top of the vertical interlock junction 10 (shown in FIG. 6) betweenthe two blocks 2 of the preceding. The present invention provides thepossibility to build a wall by using a combination of blocks 2 to startthe base course of the wall and then blocks 4 to lay additional coursesto the wall by interlocking the horizontal bottom tongue 14 (shown inFIG. 6) of a block 4 with the horizontal top continuous groove 13 (shownin FIG. 6) of the preceding row of blocks. The blocks are interlockedvertically 10 by assembling the vertical tongue 8 of a block 2 or 4 withthe vertical groove 7 of a following block 2 or 4. The blocks are set inplace with a fluid mortar or grout, and even if not necessary, it isbetter to overlap a block 4 on top of the mid vertical interlockingjunction 10 between two blocks of a preceding row of blocks 2 or 4.

FIG. 8 to 13 illustrate a method of building a reinforcing concretestructure around each block which permits building a wall with analigned concrete structure between each vertical row of blocks and ahorizontal concrete structure between each horizontal row of blocks.Referring to FIG. 8, in a first step of the method, a course of flatbottom blocks 1 are laid end-to-end to create vertical cavities 12, acontinuous horizontal groove 13 and vertical grooves 7 on the externalend faces. The vertical cavities 12 of FIG. 8 are then filled withconcrete 15 as shown in FIG. 9. The continuous horizontal groove 13 andthe vertical grooves 7 are filled with concrete 15 as shown in FIG. 10.FIG. 11 shows how a second course of flat bottom blocks 1 is set on topof the concrete-filled course shown in FIG. 10. Even if not necessary,it is better to glue the blocks together with a fluid mortar or a grout.FIG. 12 shows the second course of blocks 1 with the continuoushorizontal groove 13, the vertical cavities 12 and the vertical grooves7. FIG. 13 shows the concrete 15 filling all the grooves and cavitiesshown in FIG. 12.

The flexibility to the present invention is illustrated in FIGS. 14 to19 which show how, by selecting between blocks 2 and blocks 1 andbetween blocks 4 and blocks 3, render it possible to create at anyinterval, either vertically or horizontally, a concrete reinforcingstructure in a wall. FIG. 14 shows how the vertical tongue of a block 2is interlocked at 10 with the vertical groove of a block 1 (or block 2)where no vertical reinforcing structure is required and when a verticalreinforcing structure is required then the second groove of the block 1is positioned adjacent to the groove of a following block 2 to create avertical cavity 12. As can be seen from FIG. 14, one can assemble asmany blocks 2 or 4 as needed structurally before inserting a block 1 or3 to create a cavity 12 which can be filled with concrete 15 as shown inFIG. 15. As shown in FIG. 16, if no horizontal reinforcing structure isrequired, a subsequent course of blocks 4 and 3 is horizontallyinterlocked at 14 with the horizontal groove of the preceding course. Ascan be seen from FIG. 16 and FIG. 17, one can assemble as many rows ofhorizontally interlocking blocks as needed, and where horizontalconcrete reinforcement is required structurally, the continuoushorizontal groove 13 shown in FIG. 18 is filled with concrete 15 asshown in FIG. 19. The building versatility provided by the shapes of thefour-block system of the present invention provides the ability toadjust the structural capacity of a wall to correspond to specific loadbearing needs. With the integrated interlocking block system of thisinvention a wall can be assembled by using blocks 2 and 4 glued togetherwith a fluid mortar or grout, or a wall can be assembled with a concretestructure between each vertical row and each horizontal row of blocks byusing blocks 1 only, or the vertical and horizontal concrete reinforcingstructure can be introduced at any interval needed when assembling thewall, by using a combination of blocks 1, 2, 3 and 4. Steel rods can beused to reinforce the vertical or horizontal concrete structure asrequired. Once the wall is raised, it can be finished with a few coatsof mortar or a coat of mortar and a coat of stucco on the outside, andthe wall can be finished on the inside with a coat of mortar and coat ofplaster.

The embodiments of the invention described above are intended to beexemplary only. The scope of the invention is therefore intended to belimited solely by the scope of the appended claims.

1. A building material for the construction of building blocks, thebuilding material comprising: chopped straw; Portland cement; mortarcement or lime; and a bonding agent comprising a polymer emulsion,wherein the straw comprises the hulk of the volume of the buildingmaterial.
 2. A building material as claimed in claim 1, wherein thestraw is chopped in lengths substantially between 50 mm and 100 mm.
 3. Abuilding material as claimed in claim 2, wherein the straw comprisescereal straw.
 4. A building material as claimed in claim 3, wherein thecereal straw is selected from the group of wheat, rye, barley, oats andrice.
 5. A building material as claimed in claim 2, wherein the bondingagent further comprises at least one of: mortar cement and lime.
 6. Abuilding block formed of the building material as claimed in claim 1,the building block having a generally solid rectangular exteriorconfiguration.
 7. A building block as claimed in claim 6, the buildingblock comprising: a front face; a rear face opposite the front face; atop surface adjacent to the front face arid the rear face, the topsurface having a horizontal groove substantially parallel to the frontface; a bottom surface adjacent to the front face and the rear face, andopposite the top surface; a first end face adjacent to: the front face;the rear face; the top surface; and the bottom surface, the first endface having a vertical groove substantially parallel to the front face;and a second end face adjacent to: the front face; the rear face; thetop surface; and the bottom surface, the second end facing beingopposite the first end face.
 8. A building block as claimed in claim 7,wherein the second end face has a vertical groove, substantiallyparallel to the front face.
 9. A building block as claimed in claim 7,wherein the second end face has a vertical tongue, substantiallyparallel to the front face, the vertical tongue configured to mate witha corresponding vertical groove of an adjacent similar building block.10. A building block as claimed in claim 8, wherein the bottom surfaceis substantially flat.
 11. A building block as claimed in claim 8,wherein the bottom surface has a horizontal tongue substantiallyparallel to the front face, the horizontal tongue configured to matewith a corresponding horizontal groove of an adjacent similar buildingblock below.
 12. A building block system comprising a plurality ofbuilding blocks of claim 7, the building blocks selected from one ormore of: a first block having a horizontal groove on a top surface, aflat bottom surface, a first end face having a vertical groove and asecond end face having a vertical groove; a second block having ahorizontal groove on a top surface, a flat bottom surface, a first endface having a vertical groove and a second end face having a verticaltongue; a third block having a horizontal groove on a top surface, ahorizontal tongue on a bottom surface, a first end face having avertical groove and a second end face having a vertical groove; a fourthblock having a horizontal groove on a top surface, a horizontal tongueon a bottom surface, a first end face having a vertical groove and asecond end face having a vertical tongue, the system permitting buildingof a wall by stacking courses of blocks selected from the first block,second block, third block and fourth block such that blocks can beselected to mate vertical tongues with corresponding vertical grooves orto arrange facing vertical grooves of adjacent blocks to allow forfilling the resulting cavity with reinforcing concrete, as required. 13.A building block system as claimed in claim 12, wherein the blocks canbe selected to mate horizontal tongues of blocks in a second course withcorresponding horizontal grooves of blocks in a first course or to allowfilling the continuous horizontal groove formed by the horizontalgrooves of adjacent blocks in the first course with reinforcing concreteand subsequently stacking a second course of blocks with flat bottomsurfaces, as required.
 14. A method of constructing a wall of aplurality of courses of building blocks of claim 7, the blocks selectedfrom a set of blocks wherein: a fit block has a horizontal groove on atop surface, a flat bottom surface, a first end face having a verticalgroove and a second end face having a vertical groove; a second blockhas a horizontal groove on a top surface, a flat bottom surface, a firstend face having a vertical groove and a second end face having avertical tongue; a third block has a horizontal groove on a top surface,a horizontal tongue on a bottom surface, a first end face having avertical groove and a second end face having a vertical groove; a fourthblock has a horizontal groove on a top surface, a horizontal tongue on abottom surface, a first end face having a vertical groove and a secondend face having a vertical tongue, the method comprising steps of:laying a first course of blocks having a flat bottom surface, end-to-endsuch that where a reinforcing column is not required, adjacent blocksarm selected to mate a vertical groove of one block with a correspondingvertical tongue of an adjacent block; or where a reinforcing column isrequired, adjacent blocks are selected to present facing verticalgrooves to form a vertical cavity between the adjacent blocks; fillingany vertical cavity in the first course with reinforcing concrete; wherehorizontal reinforcement is not required, laying a subsequent course ofblocks having horizontal tongues to mate with the horizontal grooves ofthe preceding course below; or where horizontal reinforcement isrequired, filling we continuous horizontal groove formed by thehorizontal grooves of adjacent blocks of the preceding course below withreinforcing concrete and laying a subsequent course of blocks with flatbottom surfaces, end to end; and filling any vertical cavities in thesubsequent course with reinforcing concrete.
 15. A method ofconstructing a wall as claimed in claim 14, further comprising a step ofgluing adjacent blocks together with a mortar slurry.
 16. A method ofconstructing a wail as claimed in claim 14, further comprising a step ofgluing adjacent blocks together with grout.
 17. A method of constructinga wall as claimed in claim 14, wherein the vertical spaces of eachcourse align with the vertical spaces of the preceding course below. 18.A method of constructing a wall as claimed in claim 17, furthercomprising a step of placing reinforcing rods in reinforcing concrete inthe aligned vertical spaces.
 19. A method of constructing a wall asclaimed in claim 14, further comprising a step of placing reinforcingrods in the reinforcing concrete in the continuous horizontal groove.20. A method of constructing a wall as claimed in claim 14, furthercomprising a step of applying a finish coat directly to the wall, thefinish coat selected from the group of mortar, stucco and plaster.